Reactor Coil Protective Membrane for Insulation Integrity

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Solution Overview

Problem

In existing reactor manufacturing processes, foreign substances can get caught in gaps between windings, leading to damage and insulation coat peeling, which may result in short circuits due to contact with the mold during the molding process.

Innovation Solution

A reactor design where the coil's surface, particularly the boundary between adjacent turns, is covered with a protective membrane, preventing foreign substances from entering the gaps and reducing the risk of insulation coat peeling by integrating a resin mold portion that partially covers the core and coil, ensuring the coil is not damaged during molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the coil is directly placed in the mold for injection molding, then the manufacturing process is simple, but the insulation coat may peel off due to contact with the mold or foreign substances entering gaps

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidinsulation coat integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-covering the coil surface with a protective membrane before placing it in the mold for injection molding. This protective layer is applied in advance to prevent foreign substances from entering gaps between windings and to protect the insulation coat during the molding process, thereby maintaining both manufacturing simplicity and insulation integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protective membrane serves as an intermediary layer between the coil and the external environment (foreign substances and mold). This intermediate layer prevents direct contact between harmful elements and the coil, protecting the insulation coat while allowing the manufacturing process to proceed without major modifications.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the protective membrane covers the entire coil surface, then foreign substance entry is prevented, but heat dissipation is reduced

Engineering Contradiction:

Improvegap protectionVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent applies local quality by selectively covering only specific regions of the coil with the protective membrane - specifically the areas where foreign substances are most likely to enter (gaps between windings and connection portions). Regions that require heat dissipation are left uncovered, thus providing protection where needed while maintaining thermal performance where required.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of completely covering the entire coil surface, the patent uses partial action by applying the protective membrane only to critical areas that need protection from foreign substances. This partial coverage approach provides sufficient protection against the primary hazard while minimizing the negative impact on heat dissipation.

Inventive Principle:

Principle #16Partial or excessive action

3Stability of the object's composition

If foreign substances enter the gaps between windings, then the coil structure remains intact initially, but the insulation coat peels off and short circuits occur

Engineering Contradiction:

Improvecoil structure stabilityVSAvoidforeign substance contamination

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potential harm of foreign substance entry into a benefit by using the protective membrane to deliberately control and redirect the flow of molten resin during injection molding. The membrane creates a controlled path that prevents resin from entering gaps where it would cause harm, while still allowing the molding process to proceed effectively.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The protective membrane provides preliminary anti-action by preemptively blocking the entry paths of foreign substances and excess molten resin into the gaps between windings. This preventive measure is in place before the harmful substances can cause damage, thereby maintaining coil structure stability and preventing insulation coat peeling.

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentUS20230215621A1Reactor, method for manufacturing reactor, and reactor coil covering

Publication Date: 2023.07.06 TOKAI KOGYO CO LTD

AI summary

There are provided a reactor, a reactor coil covering, and a method for manufacturing a reactor, which are capable of preventing peeling off of an insulation coat with which an outer peripheral surface of a winding is covered. A reactor includes a core, a coil disposed on an outer periphery of the core, and a resin mold portion partially covering and integrating the core and the coil. A winding of the coil has an outer peripheral surface covered with an insulation coat. At least one part of a surface of the coil is covered with a protective membrane to cover a boundary between adjacent turns of the coil.